Reel-Less Cable Bundle Packaging with Radial Flaps to Prevent Unraveling
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Solution Overview
Problem
Conventional packaging systems for reel-less bundles of cable face issues such as unraveling before mounting on a reel, deformation due to stress during shipping, difficulty in removal without tools, and the need for stronger axial support.
Innovation Solution
A packaging arrangement using a planar blank that can be rolled into a cylindrical shape with radially inward flaps, providing axial crush resistance and easy attachment to maintain the bundle until mounted on a reel, made from recyclable materials like paper or fiberboard.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If shrink wrap packaging is used to maintain cable bundle perimeter, then cable is protected from unraveling, but cable deformation occurs due to stress transfer during shipping and storage
Solution Approach 1:
A collapsible tube is introduced as an intermediary component between the cable bundle and the outer packaging. The tube serves as a mediator that protects the cable from deformation during shipping and storage while allowing easy access when needed. The tube can be collapsed for compact storage and expanded to provide structural support, eliminating direct stress transfer to the cable while maintaining containment.
2Reliability
If shrink wrap packaging is used to maintain cable bundle perimeter, then cable is protected from unraveling, but difficult tool removal is required
Solution Approach 1:
The packaging system is segmented into distinct components: a collapsible inner tube, an outer packaging container, and a removable closure mechanism. This segmentation allows each component to serve its specific function independently - the tube provides structural support and cable protection, while the closure mechanism can be easily opened without tools, and the entire assembly can be collapsed for compact storage.
3Stability of the object's composition
If conventional box packaging is used for reel-less cable bundles, then cable remains contained during shipping, but cable may unravel before mounting on reel
Solution Approach 1:
A collapsible tube made of flexible material is used to enclose the cable bundle. The tube maintains the cable in a contained, organized state during shipping and storage, preventing unraveling. When needed, the tube can be easily collapsed and removed without damaging the cable, providing both containment stability and operational flexibility.
4Weight of moving object
If packaging material is made lighter to reduce weight, then shipping cost decreases, but axial strength and rigidity are reduced
Solution Approach 1:
The packaging system uses a collapsible tube that dynamically adjusts its structural properties. When expanded, the tube provides the necessary axial strength and rigidity to protect the cable bundle during shipping. When collapsed, the tube reduces to a compact form with minimal weight, allowing easy storage and handling. This dynamic transformation enables the packaging to provide strength only when needed, reducing overall weight.
Data Source
AI summary
A packaging arrangement for a bundle of cable includes a planar packaging blank extending in a longitudinal direction from a first end to a second end. The blank includes a middle region extending from the first end to the second end between a first fold line and a second fold line, a first side extending from the first end to the second end and including a plurality of first flaps extending from the first fold line in a direction away from the second side in a direction perpendicular to the longitudinal direction, and a second side extending from the first end to the second end and including a plurality of second flaps extending from the second fold line in a direction away from the first side in a direction perpendicular to the longitudinal direction. The blank is configured to be rolled into a cylindrical shape such that the first end overlaps the second end. The plurality of first flaps are configured to be folded radially inward relative to the cylindrical blank, and the plurality of second flaps are configured to be folded radially inward relative to the cylindrical blank.